Pickleball paddle

ABSTRACT

The present invention may comprise methods of fabricating a paddle with monolithic fiber composite parts. The invention may result in an integral piece, while minimizing weaknesses and manufacturing complexity. Superior paddles are produced that avoid dead spots, soft spots, laminar separation, and other disadvantages while retaining consistent rigidity and improving play during pickleball play.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from U.S. Provisional PatentApplication No. 62/065,579, filed on Oct. 17, 2014, the contents ofwhich are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates generally to paddles for sports, and inparticular, to pickleball paddles. Pickleball paddles are sometimesreferred to as pickleball rackets, pickleball racquets, bats, or otherterms.

Pickleball is played on a badminton-sized court with a net. The ball isa perforated plastic hollow ball (similar to a Wiffle Ball™) which isstruck by players using a paddle visually resembling large table tennispaddles. Pickleball paddles may be made from wood, graphite, aluminum,composite materials, and other materials.

Pickleball paddles are usually constructed by cutting or machining alarge sheet of material (called a panel) into the shape of a paddle.Another option is molding foam material into the shape of a paddle. Thehandle area is then built up with a spacer, upon which grip tape and anend cap are applied. Various types of edge treatments are usuallyapplied around the perimeter of the paddle for a finished look and toprovide protection against damage.

Pickleball paddles were originally made from a solid sheet of wood orplywood, but the heavy weight, warping issues, and poor qualityappearance made an alternative material necessary. Although some paddlesare still made from wood, a composite material has made pickleballpaddles much more lightweight without decreasing rigidity. Suchcomposite paddles are now made from a composite material that includes askin and a core.

The USA Pickleball Association (USAPA, usapa.org) is the nationalgoverning agency for pickleball. Pickleball paddle manufacturers providethe USAPA with their paddles to test and approve them for use intournaments. The USAPA requires pickleball paddles to be rigid (verylittle flex), flat, non-abrasive and within a particular size (heightand width) range. The USAPA does not require or suggest any specificmaterials or manufacturing techniques.

It is known that a pickleball paddle usually comprises a striking heador blade, which is generally flat with a rounded contour for strikingthe ball, and a handle to which the striking head is attached.Typically, the paddle material, striking head and handle contain both acore and a skin. The skin is sometimes called a “laminate” or “facesheet.” When the core material is bonded to the skin material it isusually called a “composite panel” or “sandwich panel.”

A sandwich-structured composite is a special class of compositematerials that is fabricated by attaching two thin, but stiff, skins toa lightweight, but thick, core. The core material is normally lowstrength material, but its greater thickness provides the sandwichedcomposite with both high bending stiffness and low overall density.

Open-cell-structures and closed-cell-structured foams likepolyvinylchloride, polyurethane, polyethylene or polystyrene foams,balsa wood, syntactic foams, and honeycombs are commonly used corematerials. Open-cell and closed-cell metal foam can also be used as corematerials.

Laminates of glass or carbon fiber-reinforced thermoplastics orthermoset polymers (unsaturated polyesters, epoxies, and such) arewidely used as skin materials. Sheet metal is also used as skin materialin some cases.

The core is usually, but not always, made from foam, plastic, aramid,aluminum, honeycomb or a combination thereof. The blade is covered, onat least one side and generally on both sides, with a skin, such asfiberglass, carbon fiber, aluminum, wood, plastic or graphite.

Typical paddles develop weak spots or soft spots, known as “dead spots”at locations where wear damage occurs, or where the adhesive fails,resulting in delamination of the face material from the core material.

An additional problem with the current design of paddles made fromsandwich panels arises as a result of the edge treatments. Somemanufacturers apply a u-channel or other type of molding to protect theedge and enclose the gap created by the core. This creates the problemof interference when striking the ball in this area of the paddle. Somemanufacturers finish the edge with a composite material. This rendersthe edge of the paddle overly fragile, resulting in damage if the groundor a hard object is struck during play. All previous methods offinishing the edge of the paddle have created reliability issues, as theedge treatment tends to become loose and separate or fall off with ageor stress.

Thus, it would be advantageous to have a paddle that did not require anedge treatment. This would require the paddle to be made out of a solidmaterial so that the hollow or honeycomb core is not visible on theedges. It would be further advantageous for this solid material to bestrong enough to withstand hitting the ground or other objects withoutsuffering damage.

A lightweight, rigid, and solid material without a “skin” would befurther advantageous instead of the sandwich panel, as it would serve toprevent “dead spots.” Embodiments exist for manufacturing pickleballpaddles from composite materials in a sandwiched configuration.

These various devices are cumbersome in use and construction. It wouldbe advantageous to provide a pickleball paddle that would include one ormore of the features of 1) lightweight, but of sturdy construction; 2)no delamination issues; 3) responds to striking a ball with a powerfulresponse; and 4) requires minimal edge treatments.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a paddle for a game, comprising;a substantially planar member, the substantially planar membersufficiently rigid to strike a ball, and a handle attached to thesubstantially planar member, wherein the substantially planar member iscomposed of a composite material, such as a high-density, polyurethanepanel impregnated with fiberglass fibers. The composite material may becontinuous-strand fiberglass fibers, woven roving fiberglass fibers, ora combination of the two, or any other suitable composite material. Thesubstantially planar member and the handle may be composed of oneintegral piece. The substantially planar member and the handle may bothbe substantially within the same plane or both not substantially withinthe same plane. The handle and/or the substantially planar member may becomposed of a composite material. The substantially planar member may beof any suitable shape, such as rectangular, triangular, trapezoidal, orother useful shape. The substantially planar member may be symmetricalor skewed.

In another aspect of the present invention, a paddle for a game maycomprise; a substantially planar member, the substantially planar membersufficiently rigid to strike a ball and comprising a core and a coveringfitted onto the core; and a handle attached to the substantially planarmember, wherein the substantially planar member is composed of aclosed-cell composite material and the covering is formed from a layerof elastomer.

These and other aspects, objects, features and advantages of the presentinvention, are specifically set forth in, or will become apparent from,the following detailed description of an exemplary embodiment of theinvention when read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a paddle, according to an embodiment of thepresent invention;

FIG. 2 is a plan view of a paddle, according to another embodiment ofthe present invention;

FIG. 3 is a sectional view along line A-A of the paddle in FIG. 2,according to yet another embodiment of the present invention; and

FIG. 4 is a cross-sectional view of layers in the paddle in FIG. 3,according to still another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplatedmodes of carrying out the invention. The description is not to be takenin a limiting sense, but is made merely for the purpose of illustratingthe general principles of the invention, since the scope of theinvention is best defined by the appended claims.

Although the invention is often referred to herein as a pickleballpaddle, it is understood that such description is not limiting, suchthat the technology in this invention may be applied in numerous otherproducts, including but not limited to table tennis paddles, platformtennis paddles, or other similar paddles that require a durable strikinghead. In general, the order of the steps of disclosed processes may bealtered within the scope of the invention. It should be understood thata paddle of the present invention may be used from material cut into apaddle shape, material (such as a foam material) molded into a paddleshape, or other suitable methods of manufacture.

The processes described herein constitute a means of fabricating apaddle in such a way as to eliminate the most common potential areas ofthe finished product's failure, by eliminating the requirement toassemble dissimilar materials by means of a mechanical process. Theinvention in effect creates an integral piece, without the inherentweakness and increased manufacturing complexity inherent in a process inwhich multiple elements are assembled. The invention appliesstate-of-the-art materials and processes to an existing product type,thereby enhancing production efficiency, while at the same timeimproving product performance and eliminating the most common causes ofproduct failure.

FIG. 1 shows a paddle 100 made from composite material. A substantiallyplanar member 102 (also known as a blade, head, or other names) may beattached at a neck 104 to a handle 106. The handle 106 may be coveredwith a grip 108, which may be secured to the neck 104 with a binding110. An endcap 112 may be placed at an end of the handle 106 for supportand protection of the paddle 100.

FIG. 2 illustrates a paddle 200 according to another embodiment of thepresent invention. The paddle may comprise a substantially planar member202 that is a unitary piece comprising a neck 204 and a handle 206. Agrip (for example, as shown in FIG. 1) may be applied to the handle 206.

FIG. 3 is a view in section on broken line A-A of FIG. 2. Optionally,one or more portions of the paddle 200, such as the planar member or thehandle, may be composed of a core and a covering. An exemplary displayof various layers is shown in FIG. 4. The body of the paddle 400 maycomprise a composite core 402 and one or more covering layers 404, 406.

A pickleball paddle may be constructed of a rigid core, a rigid foambonded to the rigid core after solidification of the rigid foam from aliquid state, and a handle composed of the rigid core.

A high-density polyurethane foam, polymer, or plastic may be reinforcedwith layers of fiberglass, carbon fiber, Kevlar, or any other rigidmaterial that can reinforce the foam material that surrounds and isintegrated with the core.

A liquid foam, polymer or plastic may be poured over or otherwiseapplied to woven, rigid fibers such that the foam later solidifies afterintimate contact with the woven, rigid fibers, resulting in a one-piecedurable material that does not require a skin to be bonded to thematerial.

A foamed molded item, such as a core, may be used to improveresponsiveness and make for a lightweight paddle by usingfiber-reinforced synthetic resin for a high mechanical strength.

A core material, a covering material, and an optional skin may comprisea fiber-reinforced resin matrix resin such that reinforcing fibers areimpregnated which may be arranged on both sides of the core materialcontaining reinforcing fibers in the range of reinforcing fiber tensilemodulus in the surface material may be within the range of 30-850 GPawith 40 Gpa one option. The reinforcing fiber content in the surfaceskin material may be in the range of 40 to 80 weight percent (wt %)while other suitable weight percentages may be used. The core materialbeing less dense than a resin skin material and an optionalfiber-reinforced plastic sandwich panel may have overall thickness inthe range of 0.5-20 mm, often within the range of 3-20 mm. The presentinvention may be practiced without a sandwich panel arrangement.

A method for producing a fiber-reinforced composite of the presentinvention may comprise using a mold cavity filled with expandable resinparticles. On the surface of the particle packing bodies may be formedby filling the cavity, impregnating a thermosetting resin in an uncuredmulti-layer body forming step of forming a laminate fiber reinforcementby supplying a heating medium into the mold cavity, the thermosettingresin of the uncured heating. The expandable resin particles may beheated to be foamed as well as molding a foamed item, a molding step ofdeforming the fiber reinforcement along a cavity inner surface shape byblowing gas onto expandable resin particles. A curing step may beapplied to the surface of the foamed molding of the fiber-reinforcedmaterial by curing the thermosetting resin of the fiber reinforcement.

The fiber-reinforced composite synthetic resin may comprise expandableresin particles. Other materials may be used in the production method ofthe present invention, but not particularly limited to, for example,polycarbonate resins, acrylic resins, thermoplastic polyester resins,and polymethacrylic imide resin.

These and other aspects, objects, features and advantages of the presentinvention are specifically set forth in, or will become apparent from,the description herein of an exemplary embodiment of the invention.

The foregoing description is of the best currently contemplated modes ofimplementing the invention. The description is not to be taken in alimiting sense, but is made merely for the purpose of illustrating thegeneral principles of the invention.

It should be understood, of course, that the foregoing relates toexemplary embodiments of the invention, and that modifications may bemade without departing from the spirit and scope of the invention.

Furthermore, a method may be performed in one or more sequences otherthan the sequence presented expressly herein.

This material can be turned into a pickleball paddle by machining theshape of the pickleball paddle from a single sheet of material ormolding the material info the shape of a pickleball paddle. The solidmaterial can be rounded on the edges for a better appearance.

Examples of this material are products such as “coosa panels” (availablefrom Coosa Composites, LLC, located at 105 Pardue Road, Pelham, Ala.35124, U.S.A.); “Thermo-Lite Boards” (closed cell composite manufacturedwith cross-linked polymer foam and fiberglass available from SpaceAgeSynthetics, Ltd., located at 1402 39^(th) Street NW, Fargo, N. Dak.58102, U.S.A.); Airex® PXw closed-cell fiber-reinforced sheet ofstructural foam available from Baltek, Inc. located at 5240 NationalCenter Drive, Colfax, N.C. 27235, U.S.A., a subsidiary of 3A Composites)and 3M™ Reinforced Polyurethane Foam (available from 3M Company,Industrial Adhesives and Tapes Division, located at 3M Center, Building225-3S-06, St. Paul, Minn. 55144-1000, U.S.A.).

Application of the process and technology described herein may result ina product that can be more efficiently produced, that is moreaesthetically pleasing, that provides greater consistency of function,and more reliable than products produced using other technologies.

It should be understood, of course, that the foregoing relates toexemplary embodiments of the invention and that modifications may bemade without departing from the spirit and scope of the invention as setforth in the following claims. Furthermore, a method herein describedmay be performed in one or more sequences other than the sequencepresented expressly herein.

I claim:
 1. A paddle for a game, comprising: a substantially planarmember, the substantially planar member sufficiently rigid to strike aball; and a handle attached to the substantially planar member; whereinthe substantially planar member is composed of a composite material. 2.The paddle of claim 1, wherein the substantially planar member and thehandle are composed of one integral piece.
 3. The paddle of claim 1,wherein the substantially planar member and the handle are substantiallywithin the same plane.
 4. The paddle of claim 1, wherein thesubstantially planar member and the handle are not substantially withinthe same plane.
 5. The paddle of claim 1, wherein the handle is composedof a composite material.
 6. The paddle of claim 1, wherein thesubstantially planar member has a symmetrical shape.
 7. The paddle ofclaim 1, wherein the substantially planar member has a triangular shape.8. The paddle of claim 1, wherein the substantially planar member has atrapezoidal shape.
 9. The paddle of claim 1, wherein the compositematerial comprises a polymer foam impregnated with fibers.
 10. Thepaddle of claim 9, wherein the composite material comprisescontinuous-strand fibers.
 11. The paddle of claim 9, wherein thecomposite material comprises woven roving fibers.
 12. A paddle for agame, comprising: a substantially planar member, the substantiallyplanar member sufficiently rigid to strike a ball and comprising a coreand a covering fitted onto the core; and a handle attached to thesubstantially planar member; wherein the substantially planar member iscomposed of a closed-cell composite material and the covering is formedfrom a layer of elastomer.
 13. The paddle of claim 12, wherein thesubstantially planar member and the handle are composed of one integralpiece.
 14. The paddle of claim 12, wherein the substantially planarmember and the handle are substantially within the same plane.
 15. Thepaddle of claim 12, wherein the substantially planar member and thehandle are not substantially within the same plane.
 16. The paddle ofclaim 12, wherein the handle is composed of a composite material. 17.The paddle of claim 12, wherein the substantially planar member has asymmetrical shape.
 18. The paddle of claim 12, wherein the substantiallyplanar member has a triangular shape.
 19. The paddle of claim 12,wherein the substantially planar member has a trapezoidal shape.
 20. Thepaddle of claim 12 wherein the composite material comprises polymermaterial impregnated with fibers.